Liquid level sensor

ABSTRACT

The present invention provides a liquid level sensor and an automatic calibration process which removes the need for prior manual calibration of the liquid level sensor, as this happens dynamically during installation and use of the pump. Further, by frequently monitoring the calibration of the sensor and correcting for long term drift or contamination on the sensing surface, the reliability of the liquid level sensor is considerably better than those of the prior art. By operating a solid state sensor, there are no moving parts in the liquid level sensor described above.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of, and claims the priority benefit to,U.S. patent application Ser. No. 16/762,351, filed May 7, 2020, whichclaims priority to PCT/GB2018/053094, filed Oct. 25, 2018, which furtherclaims priority to GB Patent Application No. 1718625.5, filed Nov. 10,2017, the disclosures of which are incorporated herein by reference intheir entirety

TECHNICAL FIELD OF THE INVENTION

This invention relates to a liquid level sensor for condensate pumps.

BACKGROUND

Air-conditioning (AC) units are one of the most common methods ofmaintaining the temperature of a space and often use a refrigerationcycle which requires an evaporator and condenser. This allows warm airfrom a space to be blown over a refrigerant-cooled pipe and cooledbefore being returned to the space to be conditioned. However, one ofthe issues with this approach is that condensation is formed on thepipes, as the warm humid air is cooled. This condensate is often left todrip off the pipes and is collected in a drip tray or reservoir. While asmall portable AC unit may have a reservoir that can simply be emptiedperiodically by removing the condensate reservoir, the majority of ACunits will have a reservoir that cannot be removed. In these cases, apipe may be attached to the drip tray and the force of gravity may drawthe condensate into a drain. However, if a pipe cannot be run downwardsfor the entirety of the path between the drip tray or reservoir and thedrain, a pump must be fitted to pump out the condensate within thereservoir.

Using a condensate pump to remove the condensate from the reservoirallows for a smaller reservoir to be used, which makes for a moreappealing AC unit. However, in some cases, the condensate pump may notbe able to empty the reservoir sufficiently quickly or may bemalfunctioning, which can result in an overflowing reservoir,potentially causing water to be introduced to the electronics of thesystem or any neighbouring systems. Large accumulations of condensatecan also result in water damage to floors, walls and ceilings of abuilding which can render a structure unsafe. Therefore, it is essentialthat condensate reservoirs are effectively monitored and emptied. Insuch cases, AC units will come with a high water level alert switch forshutting down the AC unit to prevent this situation. Moreover, if thecondensate level drops below a minimum level and the condensate pumpcontinues to operate, air may be entrained into the pump and downstreamconduits, which might affect the lifespan of the pump and result inincreased noise. Also, the condensate pump may rely on the liquid beingpumped as a lubricant for the pump piston.

Existing condensate pumps are often mounted within the housing of the ACunit or adjacent to the AC unit in a separate housing to minimise thetravel between the condensate reservoir and the condensate pump.However, as the pump motor operates, it causes the condensate pump tovibrate, which in turn causes the pump to rattle within the housingwhile the system is in use and generates undesirable noise.

Traditionally these pumps have been controlled by a magnetic float thatoperates magnetic switches within the pump to operate the pump and highlevel operations. A float system only provides static level indication(i.e. that the pump needs to be turned on and off) and while this isacceptable for basic control, such a system does not allow for measuringand controlling pumping flow rates through the condensate pump.Additionally, floats are mechanical devices and can be subject tophysical damage. It is also possible for the floats to become stuck tothe bottom of the condensate reservoir during prolonged periods when theAC unit is shut down, such as in winter.

Aside from magnetic floats, capacitance measurements may be used, butonly to provide level information and not flow information. However, dueto manufacturing differences, the values obtained for a given liquidlevel will have a tolerance. If this range is significant, the actuallevel measurement will be inaccurate and could cause air to be drawninto the pump at the switch-off point, creating noise and acceleratingwear of the pump motor, or the air conditioning unit would not beswitched off in the event of a fault, for example, when a reservoir isoverflowing. To account for these tolerances, capacitance-based liquidlevel sensors can be calibrated by applying a known level of liquid tothe pump and scaling it to give the correct value. Problems associatedwith having to calibrate each liquid level sensor include: thetime-consuming nature of the calibration process, which can add to thecost of operating the system; the need to use a liquid to calibrate theliquid level sensor, which means the liquid level sensor gets wet andtherefore requires careful drying to prevent damage to its packagingprior to its intended use; and the risk of human error when performingthe calibration process.

BRIEF SUMMARY OF THE DISCLOSURE

Viewed from a first aspect, the present invention provides a liquidlevel sensor having a sensor module having a first sensing elementconfigured to generate a low liquid level detection signal in responseto a liquid reaching the first sensing element, a second sensing elementpositioned above the first sensing element and configured to generate atop liquid level detection signal in response to a liquid reaching thesecond sensing element, and a level sensing element positioned betweenthe first and second sensing elements and configured to generate avariable liquid level signal in response to the liquid level risingacross the level sensing element. The first sensing element, the secondsensing element and the level sensing element are electrically connectedto a microprocessor configured to receive the low liquid level detectionsignal, the top liquid level detection signal and the variable liquidlevel signal. The microprocessor is configured to store the receivedvariable liquid level signal in a nonvolatile memory as a low liquidlevel reference value upon receipt of the low liquid level detectionsignal and to control a condensate pump in response to the receivedvariable liquid level signal. The microprocessor is also configured tocalculate an error value based on the variable liquid level signal andthe reference value, determine the operating speed of the condensatepump speed based the calculated error value, and to generate a controlsignal to operate the condensate pump at the determined speed. Thepresent invention may also include a third sensing element positionedabove the second sensing element configured to generate a high liquidlevel detection signal in response to a liquid reaching the thirdsensing element. The third sensing element is electrically connected tothe microprocessor, which would be further configured to receive thehigh liquid level detection signal.

Any of the first or second sensing elements may be electricallyconnected to the third sensing element.

Any of the low or top liquid level detection signals may be digitaloutput signals. The high liquid level detection output signal of thethird sensing element may be a digital output signal. Any of the first,second or level sensing elements may have a sensing area made of aconductive material. The third sensing element may have a sensing areamade of a conductive material. The conductive material may be copper.

Any of the first, second or level sensing elements may becapacitance-based sensors. Where any of the first, second or levelsensing elements are capacitance-based sensors, any of the first, secondor level sensing elements may be non-contact sensors. The third sensingelement may be a capacitance-based sensor. Where the third sensingelement is a capacitance sensor, the third sensing element may be anon-contact sensor.

The sensor module may have a longitudinal axis. Any of the first,second, level or third sensing elements may be aligned with thelongitudinal axis.

The first sensing element may be connected to the second sensingelement.

Any of the second or level sensing elements may have a profile formed ofat least two widths. Where the second or level sensing elements have aprofile formed of at least two widths, the profile of the level sensingelement may vertically overlap with any of the first or second sensingelements.

The level sensing element may be adjacent to any of the first or secondsensing elements. The microprocessor may be a PIC16F18856 microprocessorchip. Using this microprocessor chip is particularly advantageous as itcontains the necessary hardware to interface with one or more touchsensors that may be present on the microprocessor chip, thereby reducingthe number of components on the sensor.

The liquid sensor may form part of a condensate pump having a housing, apump motor, a condensate reservoir and a liquid level sensor mountedwithin the housing such that the liquid level sensor is located withinthe condensate reservoir and where the liquid level sensor is configuredto control the pump motor.

The method of controlling a condensate pump using the described liquidlevel sensor is believed to be novel and is thus considered from asecond aspect. The present invention provides a method of controlling acondensate pump using a liquid level sensor having the steps of:providing a sensor module having a first sensing element configured togenerate a low liquid level detection signal, a second sensing elementpositioned above the first sensing element and configured to generate atop liquid level detection signal, and a level sensing elementpositioned between the first and second sensing elements and configuredto generate a variable liquid level signal; providing a microprocessorhaving an electrical connection to each of the first sensing element,the second sensing element and the level sensing element, where themicroprocessor is configured to receive the low liquid level detectionsignal, the top liquid level detection signal and the variable liquidlevel signal, and where the microprocessor is configured to control acondensate pump in response to the received variable liquid levelsignal; storing the variable liquid level signal as a low liquid levelreference value in a non-volatile memory upon receipt of the low liquidlevel detection signal; calculating an error value from the variableliquid level signal and the low liquid level reference value storedwithin the non-volatile memory, wherein the error value is calculated asthe difference between the variable liquid level signal and the lowliquid level reference value; determining the operating speed of thecondensate pump speed based the calculated error value; and generating acontrol signal to operate the condensate pump at the determined speed.

The method may include the step of generating a control signal tooperate the condensate pump at a maximum speed in response to receivinga top liquid level detection signal.

The method may include the step of generating a control signal to shutdown the connected air-conditioning unit in response to receiving a highliquid level detection signal.

The method may include the step of storing the value of the liquid levelsignal as a top liquid level reference value in the non-volatile memoryupon receipt of the top liquid level detection signal.

The method may include the step of storing the value of the liquid levelsignal as a high liquid level reference value in the non-volatile memoryin response to receipt of the high liquid level detection signal.

Thus, the present invention provides a liquid level sensor and anautomatic calibration process which removes the need for prior manualcalibration of the liquid level sensor, as this happens dynamicallyduring installation and use of the pump. Further, by frequentlymonitoring the calibration of the sensor and correcting for long termdrift or contamination on the sensing surface, the reliability of theliquid level sensor is considerably better than those of the prior art.By operating a solid state sensor, there are no moving parts in theliquid level sensor described above.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of facilitating an understanding of the subject mattersought to be protected, there is illustrated in the accompanying drawingembodiments thereof, from an inspection of which, when considered inconnection with the following description, the subject matter sought tobe protected, its construction and operation, and many of itsadvantages, should be readily understood and appreciated.

FIG. 1 is an illustration of a prior art liquid level sensor;

FIG. 2 shows a typical output of such a prior art liquid level sensor;

FIG. 3 shows the uncertainty in the output of such a prior art liquidlevel sensor;

FIG. 4 is a perspective view of an exemplary liquid level sensor andcondensate reservoir arrangement;

FIGS. 5 a and 5 b are a schematic layout of the circuits used tocalculate the output value of a liquid level sensor;

FIG. 6 a is an exemplary liquid level sensor having two sensing elementsand a level sensing element;

FIG. 6 b shows the output of the liquid level sensor shown in FIG. 6 a;

FIG. 7 a is an alternative liquid level sensor having a single sensingelement formed of two sensing regions connected by a connecting regionand a level sensing element;

FIG. 7 b shows the output of the liquid level sensor shown in FIG. 7 a;

FIG. 8 a is an exemplary liquid level sensor having three sensingelements and a level sensing element;

FIG. 8 b shows the output of the liquid level sensor shown in FIG. 8 a;

FIG. 9 a is an exemplary liquid level sensor having two sensing elementsand a level sensing element having a profile formed of two widths;

FIG. 9 b shows the output of the liquid level sensor shown in FIG. 9 a;

FIG. 10 a is an exemplary liquid level sensor having a single sensingelement formed of three sensing regions connected by a connecting regionand a level sensing element having a profile formed of two widths;

FIG. 10 b shows the output of the liquid level sensor shown in FIG. 10a;

FIG. 11 a is an exemplary liquid level sensor having two sensingelements and a level sensing element having a profile formed of threewidths;

FIG. 11 b shows the output of the liquid level sensor shown in FIG. 11a;

FIG. 12 shows a calibration process for a liquid level sensor;

FIG. 13 shows a sensor module including a notch substantially the widthof the sensing element.

DETAILED DESCRIPTION

While the present invention is susceptible of embodiments in manydifferent forms, there is shown in the drawings, and will herein bedescribed in detail, a preferred embodiment of the invention with theunderstanding that the present disclosure is to be considered as anexemplification of the principles of the invention and is not intendedto limit the broad aspect of the invention to embodiments illustrated.As used herein, the term “present invention” is not intended to limitthe scope of the claimed invention and is instead a term used to discussexemplary embodiments of the invention for explanatory purposes only.

FIG. 1 is an illustration of a prior art capacitance-based liquid levelsensor 30. The liquid level sensor 30 is arranged within a container 10which contains a liquid 20 at a liquid level 40. The liquid level sensor30 is shown as a simple rectangular sensor partially submerged in theliquid 20 within the container 10.

FIG. 2 shows a typical output of a liquid level sensor 30 such as thatshown in FIG. 1 . When the container 10 contains liquid 20 at a level 40below the liquid level sensor 30, there is no change in the output valueof the liquid level sensor 30. This is the case until the liquid level40 rises sufficiently to contact the liquid level sensor 30 (“A”).Beyond liquid level “A”, the output value of the liquid level sensor 30changes with the rising liquid level. As shown, the output value changeslinearly with rising liquid level 40; however, other output profiles areconceived by this description. The output value of the sensor willcontinue to increase until the liquid level 40 rises to the top of theliquid level sensor 30 (“100%”) and will stay at this point even if theliquid level 40 increases beyond the top of the liquid level sensor 30.

Tolerances arising from differences in the manufacturing process meanthat liquid level sensors 30 typically require calibration to functionproperly in order to return an output value that corresponds to the trueliquid level 40. FIG. 3 shows uncertainties in the output of a liquidlevel sensor 30 due to manufacturing tolerances. The bounds ofuncertainty (“Upper limit” and “Lower limit”) associated with the outputof the liquid level sensor 30 are shown around the “Nominal” responseoutput. At a given liquid level, such as “B” shown in the Figure, apoorly calibrated sensor may return an output value within the range ofBupper and Blower. While this may be acceptable when the liquid level 40is not near the maximum level of the container 10, as the liquid level40 approaches the top of the container 10 or bottom of the sensor 30, itis important to have accurate sensor outputs, as the sensor outputs aspecific value when the liquid is at a specific level. If the sensor ispoorly calibrated or if the sensor has not been calibrated for a longperiod of time, an output value which corresponded to a liquid level of90% capacity at the time of calibration may actually be indicative of anoverflowing container 10. Similarly, an output value which correspondedto a liquid level of 10% capacity at the time of calibration, mayactually correspond to a liquid level below the sensor. Operating thepump when the liquid level is below the sensor is not desirable, as theliquid 20 being pumped acts as a lubricant for the pump motor. If theliquid level 40 decreases to the extent that there is negligible liquidin the container, the pump will have to restart from a ‘dry’ state,which is poor from a wear point of view and also increases thelikelihood of air being drawn into the pump, both of which might lead toparticularly noisy operation and reduced operational lifespan of thepump.

FIG. 4 is a perspective view of an exemplary liquid level sensor andcondensate reservoir arrangement. The arrangement includes a liquidlevel sensor 100 connected to a pump motor 150 and a microprocessor 140via electrical connections 130. The microprocessor may be a PIC16F18856microprocessor chip and may have a non-volatile memory. Thismicroprocessor chip is suited to the present invention as it containsthe necessary hardware to interface with one or more touch sensors thatmay be present on the microprocessor chip, thereby reducing the numberof components on the sensor. The touch sensors may be used to manuallyinitiate specific condensate pump operations, such as the calibrationprocess. While a PIG 16F18856 chip is preferable to other microprocessorchips, other chips may be used in combination with other measurementtechniques, such as capacitance to frequency conversion. The liquidlevel sensor 100 has a sensor module 110 and a sensing element 120.Typically, the sensing element 120 is formed of a conductive plate. Theconductive material may be copper. Typically, the liquid level sensor100 is located within a housing (not shown) that is attached to aconnecting portion 170 which attaches to a condensate reservoir 160. Theconnecting portion 170 contains a slot 180 and an associated receptacle183 which enables the liquid level sensor 100 to be easily positionedwithin the volume of the condensate reservoir 160. Preferably, thesensor module 110 has a substantially planar elongate form and thesensing element 120 is located on the sensor module 110, as this allowsthe sensor module to be easily positioned within the volume of thereservoir 160. The sensor module 110 may include a notch 115 across thewidth of the sensor module 110 (see FIG. 13 ). The notch 115 may bev-shaped and may also be substantially the width of the sensing element120. The notch 115 may be run in a substantially horizontal direction.The notch 115 allows the sensor module 110 to flex about an axis duringoperation. This is desirable, as it allows the sensor 110 to beinstalled in a configuration where the sensing element 120 is pressedagainst the inner surface of the receptacle 183. This would ensure thesensing element 120 maintains optimal contact with the internal surfaceof the receptacle 183 and that the readings provided by the sensorremain accurate during operation of the pump motor 150. This sensormodule 110 arrangement occupies a minimal amount of space within thecondensate reservoir 160 and results in a connecting portion 170 that issimpler to design and easier to manufacture. However, it is within thescope of the present description to arrange the sensing elements 120 ona sensor module 110 with a non-planar form, such as a cuboid orcylinder, to obtain the benefits of the present invention. Such a sensormodule 110 would be equally functional where space was not a concern.Liquid level sensors may rely on physical contact between the liquid 20and the liquid level sensor 100 to cause a change in output value of theliquid level sensor 30, as the liquid contact causes a change inresistance or capacitance of the sensing element 120 which leads to acorresponding change in output value. In the case of capacitance-basedsensors, it is possible to measure the liquid level in a non-invasivemanner that does not require the liquid 20 to physically contact theliquid level sensor 100. Such sensing capabilities are achieved by thearrangement shown in FIG. 4 , which locates the liquid level sensor 100within a receptacle 183 which has thin walls to separate the liquidlevel sensor 100 from the liquid 20, but keeps the liquid level sensor100 in close proximity to the liquid 20 such that the liquid level 40 isstill able to pass across the sensing surface 120 of the liquid levelsensor 100. Non-contact or non-invasive liquid level measurement isparticularly desirable as it enables the electronics and electricalcomponents of the liquid level sensor 100, such as the microprocessor140 and electrical connections 130, to be housed separately in awaterproof housing away from the liquid 20 contained within thecondensate container 10. The non-contact or non-invasive sensingdescribed may also be considered indirect sensing of the liquid.However, it would be understood that contact sensors arranged in asimilar manner to that of the present invention would also benefit fromthe present invention. Where contact sensors are used, they may beindividual sensors arranged around the inner surface of the condensatereservoir 160, or arranged on a similar or non-planar sensor module,where the sensor module is in direct contact with the liquid within thereservoir 160. Where direct contact is made between the liquid andsensor, a thicker sensor cross section may provide a more stable androbust sensor module. The arrangement of FIG. 4 may form part of acondensate pump having a housing to support the liquid level sensor 100,a pump motor 150 and a condensate reservoir 160 attached to the housing.The housing of the condensate pump may also be configured to locate theliquid level sensor 100 within the condensate reservoir 160. The liquidlevel sensor 100 may be configured to control the pump motor 150.

The liquid level 40 in the condensate reservoir 160 is calculatednoninvasively by measuring the capacitance through the walls of thereceptacle 183 to the liquid 20. The measurement is completely solidstate as the sensor 100 contains no moving parts. The present inventionmeasures the output voltage of a reference capacitor and compares thisvoltage to the voltage of the liquid level sensor 100. The approach isparticularly advantageous, as it uses the internal capacitors of themicroprocessor as reference capacitors, negating the need for additionalcomponents. The measurement process is in two stages illustrated inFIGS. 5 a and 5 b . The combined results are used to provide the liquidlevel value.

FIGS. 5 a and 5 b show a schematic layout of the circuits used tocalculate the output value of a liquid level sensor of the kindillustrated in FIG. 4 . FIG. 5A shows an internal capacitor (“Cref”)being charged to 5V, and an external capacitor (“Clevel”) beingdischarged to 0V. The charged internal capacitor is then connected tothe external capacitor which results in the external capacitor beingcharged and a voltage (“V1”) being formed across the two capacitors.This voltage is recorded by the microprocessor. FIG. 5 b shows theinternal capacitor (“Cref”) being grounded and discharged to 0V and theexternal capacitor (“Clevel”) being charged to 5V. The capacitors arethen connected together and a voltage (“V2”) is developed as theinternal capacitor is charged by the external capacitor. This value isalso recorded by the microprocessor. The final value used to indicatethe liquid level is calculated by subtracting V1 from V2. This way ofcalculating the liquid level provides an output that is relative to thevalue to the internal capacitor, which thereby counteracts any changeswithin the measurement system, such as changes in supply voltage.

FIG. 6 a is an exemplary liquid level sensor having two sensing elementsand a level sensing element. A portion of the sensor module of theliquid level sensor 200 is omitted for clarity. The liquid level sensor200 may be of the kind illustrated in FIG. 4 . The first sensing element210 acts as a bottom switch and is used to indicate the pump off levelto prevent the pump running dry when the liquid level is below the pumpmotor. The second sensing element 230 may be a top switch used toindicate a top liquid level or a high liquid level. The top liquid levelmay indicate the liquid is at a maximum acceptable level and that thepump may need to be operated in a boost mode to rapidly reduce theliquid level, and the high liquid level may indicate the liquid level istoo high and that the AC unit needs to be shut down to prevent furtherrising of the condensate. The top switch may be used to indicate eitheror both the top and high liquid levels. The level sensing element 220 isadjacent to both the first sensing element 210 and the second sensingelement 230 and is used to calculate the liquid level within thecondensate reservoir according to the method described above, using theschematic circuit layouts shown in FIG. 5 . As shown in FIG. 6 a , thesensing elements 210, 220 and 230 are arranged along a longitudinal axis240 of the sensor module 200 and the longitudinal axis is substantiallyvertical. The level sensing element 220 is shown adjacent to the first210 and second 230 sensing elements. Where the sensing elements aredescribed as being aligned with the longitudinal axis, this alsoincludes the sensing elements being aligned along or arranged with thelongitudinal axis. The sensor elements in this case would be arranged ina line. It is possible to have the sensing elements 210, 220, 230aligned along the longitudinal axis, but spaced from one another.Further, it may be possible to arrange the sensing elements 210, 220,230 adjacent to one another where the sensing elements are substantiallyside-by-side to one another with minimal vertical or horizontal offsetbetween the sensing elements 210, 220, 230. However, it is preferable toarrange the sensing elements 210, 220, 230 such that they overlap oneanother when viewed along the longitudinal axis. This preferredembodiment advantageously allows for a more compact sensor module 200 asthe sensing elements are arranged close together. However, it would beapparent that this is not essential to the invention. As part of thesetup process during manufacture, the dry values of each of the sensingelements are recorded as reference values. FIG. 6 b shows the output ofthe liquid level sensor shown in FIG. 6 a . Each of the sensing elementshas an output corresponding to whether or not liquid has reached thelevel of the given sensor. As the liquid level rises to the firstsensing element (“Low”), a low liquid level detection signal isgenerated indicating the liquid has reached the level (“L”) of the firstsensing element 210 and that the liquid level is low. Upon reachingliquid level “L”, there is a change in the output value of the firstsensing element 210 from a first value to a second value which is sentto the microprocessor 140. The first sensing element 210 may indicatethe liquid level has reached the bottom switch by outputting a digitaloutput signal. As the liquid level rises further, it contacts the levelsensing element 220 and rises across its surface, causing the “Level”signal to increase accordingly. As the liquid level continues to rise,it will eventually pass above the level sensing element 220 and thevariable liquid level signal will stop changing. As the liquid levelcontinues to rise it reaches a top liquid level (“T”) and contacts thesecond sensing element 230. At this point there will be a change in the“Top” output value from a first value to a second value which is sent tothe microprocessor 140 as a top liquid level detection signal,corresponding to a top liquid level. Having a Top sensor 230 provides away of independently detecting when the liquid level has reached themaximum or top liquid level and may be used to operate a condensate pumpmotor 150 at maximum speed to prevent the condensate reservoir 160 fromoverflowing. The condensate pump 150 may be operated at the maximumspeed until the liquid level drops to the ‘zero’ reference point and thepump is switched off. As described above, instead of being a top liquidlevel sensor, the second sensing element 230 may be a high liquid levelsensor which sends a high liquid level detection signal to themicroprocessor 140 and causes the AC unit to shut down and prevent theliquid level from rising any further. Either of the top or high liquidlevel switches may send a digital output signal to indicate the liquidlevel has reached the second sensing element.

FIG. 7 a is an alternative liquid level sensor 300 having a singlesensing element 310 formed of two sensing portions 330, 340 connected bya connecting portion 350, and a separate level sensing element 320. Thesingle sensing element 310 has a profile comprising two horizontalportions 330, 340 and a vertical connecting portion 350. The horizontalportions 330, 340 are interconnected both physically and conductively bythe vertical connecting portion 350 and would typically comprise asingle unitary member. The level sensing element 320 is disposed in theregion between the horizontal portions 330, 340 that is not occupied bythe vertical connecting portion 350 and is physically separate therefromto ensure no electrical conduction between the sensing element 310 andthe sensing element 320. A portion of the sensor module of the liquidlevel sensor 300 is omitted for clarity. The liquid level sensor 300 maybe of the kind illustrated in FIG. 4 . In this embodiment, the profileof the sensing element 310 is formed of two sensing portions 330, 340.Even though the two sensing portions 330, 340 are electrically connectedby a connecting portion 350, the sensing element 310 is able to providethe same functionality to that of the first and second sensing elements210, 230, as explained below. FIG. 7 b shows the output of the liquidlevel sensor shown in FIG. 7 a . The first sensing portion 330 providesa “Low” detection signal which corresponds to when the liquid level hasreached a low liquid level (“L”). At this point, with a dropping liquidlevel, the pump motor is switched off to prevent the liquid level fromdropping below the level of the pump motor and causing air to be drawninto the pump motor and generating significant noise in operation.Conversely, from a pump off condition and with a rising liquid level,when the liquid level rises to reach the low liquid level (“L”), the lowdetection signal is used to turn the pump on. The second sensing region340 may provide a “Top” detection signal which corresponds to when thepump should be run at a maximum speed as the liquid level has reached atop liquid level (“T”). As an alternative, the second sensing region 340may provide a high liquid level detection signal which corresponds towhen the AC unit should be shut down to prevent further condensate beinggenerated and the condensate reservoir from overflowing. In both cases,the same sensing element 310 provides the detection signal for the Lowand the Top/High level switches. The two detection signals from thefirst sensing element 310 indicating either of the bottom or top/highlevel switches, corresponding to the two respective sensing portions330, 340, may be in the form of a digital output. The digital output maybe of different amplitudes as shown in FIG. 7 b . In between the low(“L”) and top (“T”) liquid levels, the level sensing element 320operates in substantially the same manner as level sensing element 220described above and provides a variable liquid level signalcorresponding to the liquid level rising across the level sensingelement 320. While it is an advantage to use a single sensor to providemultiple detection signals as this reduces the number of sensor circuitson the liquid level sensor, the present invention does not require it.

FIG. 8 a is an exemplary liquid level sensor having three sensingelements and a level sensing element. The three sensing elements 410,430 and 440 are arranged substantially along a vertical longitudinalaxis of the sensor module (not shown). A portion of the sensor module ofthe liquid level sensor 400 is omitted for clarity. The liquid levelsensor 400 may be of the kind illustrated in FIG. 4 . In thisembodiment, the first, “Low” sensing element 410 and level sensingelement 420 operate in substantially the same manner as the firstsensing element 210 and level sensing element 220 of FIG. 6 a . Whereliquid level sensor 400 differs from other embodiments is in having aseparate top sensing element 430 and high level sensing element 440.This allows for the pump motor 150 to operate at a maximum speed whilethe top liquid level detection signal has been communicated to themicroprocessor 140 before a separate high liquid level detection signalis received by the microprocessor 140 indicating the AC unit should beshut down.

FIG. 8 b shows the output of the liquid level sensor shown in FIG. 8 a .The sensor operates in substantially the same manner as that shown inFIG. 6 b , with the difference being the presence of a separate highliquid level sensing element 440 which provides a further output signalto the liquid level sensor. When the liquid level reaches the highliquid level (“H”), a high liquid level detection signal (“High”) isgenerated and sent to the microprocessor 140. The microprocessor 140 canthen send a control signal to shut down the AC unit to prevent furthercondensate being generated and the liquid level from rising any further.Therefore, the pump motor 150 can operate at a maximum speed when a topliquid level detection signal has been received, but prior to a highliquid level detection signal. It is advantageous to have multiplesensor elements, as failure of one of the sensing elements does notrender the liquid level sensor unusable. The remaining sensing elementsare able to provide a liquid level sensor with the remainingfunctionality of those sensing elements, such as high liquid levelalerts. While it is advantageous to include multiple sensing elements,it is not essential to the invention.

FIG. 9 a is an exemplary liquid level sensor having two sensing elementsand a level sensing element having a profile formed of two widths. Thefirst sensing element 510 acts in substantially the same manner as thebottom switches 210, 330 and 410 described in earlier embodiments. Wherethis embodiment differs from previous embodiments is in the arrangementof the level sensing element 520 and the second sensing element 530. Thesecond sensing element 530 has a substantially L-shaped profilecomprising two integral sensing portions 540 and 550 of differentwidths. The two sensing portions 540 and 550 operate in substantiallythe same manner as that of the top liquid level sensor 430 and highliquid level sensor 440 of FIG. 8 a and provide indications of when aliquid level is at a top liquid level and a high liquid level. As shownin FIG. 9 a , the two sensing portions 540 and 550 are electricallyconnected and have a profile formed predominantly of two widths; thesensing portion 540 having a width approximately half that of theadjacent sensing portion 550 immediately above. The level sensingelement 520 has a correspondingly shaped stepped profile at its upperend, immediately below the second sensing element 530. The profiles ofthe level sensing element 520 and the second sensing element 530 aresuch that the two sensing elements are able to vertically overlap withone another. As shown, the portion of the level sensing element 520nearest the high liquid level sensing portion 550 is approximately halfthat of the width at the end nearest the first sensing element 510. Thischange in width causes a change in the output value for both the levelsensing element 520 and the second sensing element 530, shown in FIG. 9b . In this embodiment, the variable liquid level signal from levelsensing element 520 will increase linearly until the liquid levelreaches a top (“T”) level, at which point the change in width of thelevel sensing element 520 will result in a different rate of change invalue (assuming a constant rate of rising liquid). The output value willchange at this different rate until the liquid level reaches a highlevel (“H”), at which point the output value will stop changing. Thesecond sensing element 530 generates a top liquid level detection signalwhich corresponds to the liquid level reaching the top sensing region540 (“Top”). The second sensing element generates a further detectionsignal corresponding to the liquid level reaching the sensing region 550(“High”). The detection signals from the second sensing element 530,indicating the top or high level switches, may be in the form of adigital output. The digital output may be of different amplitudes shownin FIG. 9 b and should not be treated as being shown to scale.

FIG. 9 b shows the output of the liquid level sensor shown in FIG. 9 a .This embodiment results in a more compact liquid level sensor, as theprofiles of the level sensing element 520 and the second sensing element530 overlap with one another along the longitudinal axis of the sensormodule without losing any of the functionality of having a furtherseparated sensing element, such as shown in FIG. 8 a.

FIG. 10 a is an exemplary liquid level sensor having a single sensingelement formed of three sensing regions connected by a connecting regionand a level sensing element having a profile predominantly formed of twowidths. The sensing element 610 has a first sensing portion 630, asecond sensing portion 640 and a third sensing portion 650. The firstsensing portion 630 is physically and electrically connected to thesecond sensing portion 640 by the connecting portion 660. Thisembodiment functions in substantially the same manner as that shown inFIG. 9 b , where the first sensing portion 630 acts as a bottom switchsensor, second sensing portion 640 acts as a top switch sensor and thethird sensing portion 650 acts as a high level switch sensor. Where thisembodiment differs from that of FIG. 9 is the first, second and thirdsensing portions are electrically connected to one another to have thebottom switch, the top switch and the high level switch all formed onthe same integral sensing element 610. In this embodiment, the sensingelement 610 has a profile predominantly formed of three distinct widthsto provide the different sensing regions 630, 640 and 650. The levelsensing element 620 has a correspondingly stepped profile and provides avariable liquid level signal in response to the liquid level crossingthe level sensing element 620 and functions in substantially the samemanner as the level sensing element 520 of FIG. 9 a.

FIG. 10 b shows the output of the liquid level sensor 600 shown in FIG.10 a . This embodiment differs from that of FIG. 9 b , as the sensingelement 610 will provide three detection signals (“Low”, “Top” and“High”) corresponding to the liquid level reaching the first, second andthird sensing portions respectively. This is an alternative to havingtwo separate sensing elements 510 and 530 provide the three detectionsignals, such as in the embodiment shown in FIG. 9 a . The threedetection signals from the sensing element 610 indicating the bottom,top and high liquid level switches may be digital outputs. The digitaloutput may be of different amplitudes, such as shown in FIG. 10 b.

FIG. 11 a is an exemplary liquid level sensor having two sensingelements and a level sensing element having a profile formed of threewidths. The first sensing element 510 acts in substantially the samemanner as the bottom switches 210, 330, 410 and 510 described in earlierembodiments. Where this embodiment differs from previous embodiments isin the arrangement of the level sensing element 720 and the secondsensing element 730. The second sensing element 730 has a profilepredominantly formed of two widths which provide the two sensingportions 740, 750. The two sensing portions 740, 750 operate insubstantially the same manner as that of the top liquid level sensor 540and high liquid level sensor 550 of FIG. 9 a and provide indications ofwhen a liquid level is at a top liquid level and a high liquid level.The two sensing portions 740, 750 are shown as being electricallyconnected, but this is not essential. The level sensing element 720 hasa profile predominantly formed of three widths, while the second sensingelement 730 has a profile predominantly formed of two widths. Thisallows the second sensing element 730 and level sensing element 720 tovertically overlap with one another and provide a more compact form thanthat shown in earlier embodiments. The change in width of the levelsensing element 720 causes a change in the output value for both thelevel sensing element 720 and the second sensing element 730, shown inFIG. 11 b.

FIG. 11 b shows the output of the liquid level sensor shown in FIG. 11 a. In this embodiment, the variable liquid level signal outputted bylevel sensing element 720 will increase until the liquid level is at atop level (“T”), at which point the change in width of the level sensingelement 720 will result in a different rate of change in value (assuminga constant rate of rising liquid). The output value will change at thisdifferent rate until the liquid level reaches a high level (“H”) atwhich point the output value will change at yet another rate due to thethird width of the profile. The output value will continue to rise untilthe liquid level passes the top of the level sensing element 720, atwhich point the output value will stop rising. Unlike previouslydescribed embodiments, the output value of the level sensing element 720continues to change even after the high level signal is sent. In thiscase, the high level signal would not shut down the AC unit and theliquid level would continue to rise. This may be in cases wherecontinued operation of the AC unit and risking an overflowing condensatereservoir is preferable to shutting down the AC unit. Examples of suchscenarios may be medicinal products that need to remain chilled orfrozen, food storage facilities or computer server rooms. Therefore, thehigh level detection signal may not shut down an AC unit, but willinstead transmit a signal to a building management system indicative ofthe high liquid level, which may alert a building maintenance worker ofa potential fault or problem with the condensate pump and to investigatethe issue. While the embodiments shown illustrate the bottom switchbeing below the level sensor, this is not essential. The bottomcalibration sensor may overlap with the level sensor provided thecalibration point on the bottom switch is above the lowest permittedwater level. In this case triggering the bottom switch will cause themicroprocessor to read and store the level sensor value as the referencelevel used to control the pump motor function.

FIG. 12 shows a calibration process for a liquid level sensor. Thepresent invention also extends to an automatic calibration process suchas that shown in FIG. 12 for a liquid level sensor having a firstsensing element, a second sensing element, a third sensing element and alevel sensing element. FIGS. 8 a, 9 a, 10 a and 11 a provide examples ofsuch liquid level sensors. The calibration process is described below.When the pump is started up 800, the microprocessor will determinewhether the pump has been calibrated 805 and if not will automaticallyinitiate the calibration process. The calibration process may begin bychecking for a calibration flag being set in the microprocessor. If thecalibration flag has not been set, this may indicate to themicroprocessor that the pump has not been calibrated. The calibrationprocess itself involves allowing the condensate reservoir to fill sothat the liquid contained within the condensate reservoir passes each ofthe sensing elements in turn, before storing the variable level sensorvalue as a particular reference value for the detected liquid level. Asthe liquid level rises in the condensate reservoir it will pass thelevel of the first sensing element 815. This will cause the output valueof the first sensing element to change. This may be in a digital manner,where the change is step-like, similar to closing a switch. This changein output value will be received by the microprocessor and will signifyto the microprocessor to store the output value of the level sensingelement as a ‘pump off’ or ‘zero’ reference value in the non-volatilememory of the microprocessor 820. The ‘pump off’ point is the point atwhich the pump should be switched off to prevent the reservoir runningdry and air to be drawn into the pump motor. This is particularlyimportant, as retaining a volume of water in the reservoir keeps thepump motor lubricated. The ‘zero’ point of the sensor is used tocalibrate the water level sensor, and provide a zero point for the errorsignal. The pump switches of when the water level reaches the ‘zeropoint’. The way in which the ‘pump off’ point is used to control theoperating speed of the pump motor will be described in greater detail inthe subsequent description. The process proceeds to step 825, where themicroprocessor determines whether the sensor has been calibrated to allliquid levels. As only the bottom sensor has been calibrated, thecalibration process returns to step 805 and the calibration cyclecontinues. When the process returns to step 815, the microprocessor isdetermining whether the bottom sensor has changed since the last cycleof the calibration process. As the bottom sensor remains activated, ithas not changed its state since the previous cycle and therefore theprocess continues to step 830.

As the liquid level continues to rise, the liquid level will eventuallyreach the top switch 830, at which point a change in output value of thesecond sensing element will be detected by the microprocessor. Thischange in output value causes the microprocessor to store the outputvalue of the level sensing element as a ‘max value’ reference point inthe nonvolatile memory of the microprocessor 835. The ‘max value’reference point indicates the maximum allowable value of the levelsensing element, as this corresponds to the highest acceptable liquidlevel. The process continues from step 835 to step 825, and as thesensor has not been calibrated for all levels, the process returns tostep 805 and the calibration cycle continues to step 840.

As the liquid level continues to rise, eventually it will reach the highlevel sensor 840. At this point, the third sensing element will changeits output value, which will be detected by the microprocessor.Receiving the detection signal of the high liquid level sensor resultsin the value of the level sensing element being stored as a ‘high level’reference value in the nonvolatile memory of the microprocessor 845.This reference value indicates the point at which liquid level is toohigh and the AC unit should be shut down. The calibration process passesfrom step 845 to step 825 and as the sensor has been calibrated for allof sensor levels 825 and all of the reference values have been stored, acalibration flag can be set in the microprocessor 850. As the processreturns to step 805, because the calibration flag has been set, thesensor exits the calibration process and is controlled in the normalmanner 810. It should be noted that while step 805 is included in eachcycle of the calibration process, it is equally possible that this stepis only performed once after initiation of the pump 800. In this case, anegative outcome from step 825 would cause the microprocessor to proceedto step 815 directly. A positive outcome from step 825 would proceed tostep 850 and directly to step 810. Such an approach would require fewerprocesses to be performed in each cycle of the calibration process.While a cycle-based calibration process has been described, themicroprocessor may simultaneously monitor the inputs from all switchsensors, and as each switch sensor is activated, by the liquid levelpassing each sensor in turn, the microprocess may read the variableoutput from the liquid level sensor and store the variable output valuecorresponding to each switch sensor as a reference value for each liquidlevel. It should be noted that the three references values stored atsteps 820, 835 and 845 are not used to control the operation of thepump. The reference values are indicators for the calibration process.The pump can periodically use the three reference values to check thevalidity of the calibration, as over time it is possible thatcontaminants can build up on the sensor face and reduce its sensitivity.However, by periodically recalibrating the liquid level sensor in themanner described, it is possible to ensure the pump operates properly.

A method of controlling the pump motor will now be described. Unlikeprior art systems, the pump motor is not switched on and off at discretepoints. The ‘pump off’ or ‘zero’ reference value determined by thecalibration process described above is used as a reference value tocontrol the pump motor speed. As the liquid level rises, the levelsensing element will output a variable liquid level signal. This liquidlevel signal is compared to the reference value and forms an errorvalue. The error value is taken to be the ‘pump off’ reference valuestored in the non-volatile memory of the microprocessor subtracted fromthe current output value of the variable liquid level signal. This errorvalue determines the operating speed of the condensate pump. As theerror value increases, the pump motor operating speed increases. Thepump will continue to operate until the liquid level equals thereference level, at which point the pump will be switched off.Additional factors, such as how quickly the reservoir isfilling/emptying may be factored into the pumping rate calculation toapply an optimal outflow rate and minimise the noise generated by thepump. This is especially important, as only increasing the outflow ratewhen necessary results in a noise-efficient pump, because noiseassociated with the pump motor operating is only generated whennecessary, such as when the liquid level is at the top liquid level.While it is preferable to control the condensate pump motor using onlythe level sensor in the manner described above, the bottom, top and highlevel sensors may be used to provide an alternative control method toensure the pump operates correctly, for example when the liquid levelsensor becomes contaminated or fails.

The sensing elements described may be conductive traces or areas of aconductive material on a printed circuit board (PCB). The conductivematerial may be copper.

The figures show the sensing elements are arranged substantially aboveone another, with the first sensing element positioned at the bottom ofthe sensor module, the level sensing element positioned above the firstsensing element and the second sensing element positioned above thelevel sensing element. Where present, the third sensing element ispositioned above the second sensing element. However, while preferableto have the sensing elements arranged vertically above one another onthe sensor module, it is not essential. The present invention wouldapply equally well to a series of sensors located separately within theinterior volume of a fluid reservoir provided that the bottom sensingelement was located below the level sensor and the top sensing elementwas located above the level sensing element.

While the shape of the sensing elements have been shown as beingsubstantially rectangular, or having a profile with two or three widths,sensing elements of other shapes are encompassed by this description,such as shapes with tapered or rounded ends or edges. More complexshapes may result in non-linear output values from the liquid levelsensor. However, the combination of a level sensing element thatproduces a variable liquid level signal coupled with at least onesensing element to produce a detection signal enables the method ofcalibration and control of the liquid level sensor described above to beapplied equally well to sensing elements formed of such complex shapes.

The present invention provides a liquid level sensor and an automaticcalibration process which removes the need for prior manual calibrationof the liquid level sensor, as this happens dynamically duringinstallation and use of the pump. Further, by frequently monitoring thecalibration of the sensor and correcting for long term drift orcontamination on the sensing surface, the reliability of the liquidlevel sensor is considerably better than those of the prior art. Byoperating a solid state sensor, there are no moving parts in the liquidlevel sensor described above.

Throughout the description and claims of this specification, the words“comprise” and “contain” and variations of them mean “including but notlimited to”, and they are not intended to (and do not) exclude othermoieties, additives, components, integers or steps. Throughout thedescription and claims of this specification, the singular encompassesthe plural unless the context otherwise requires. In particular, wherethe indefinite article is used, the specification is to be understood ascontemplating plurality as well as singularity, unless the contextrequires otherwise. Features, integers, characteristics, compounds,chemical moieties or groups described in conjunction with a particularaspect, embodiment or example of the invention are to be understood tobe applicable to any other aspect, embodiment or example describedherein unless incompatible therewith. All of the features disclosed inthis specification (including any accompanying claims, abstract anddrawings), and/or all of the steps of any method or process sodisclosed, may be combined in any combination, except combinations whereat least some of such features and/or steps are mutually exclusive. Theinvention is not restricted to the details of any foregoing embodiments.The invention extends to any novel one, or any novel combination, of thefeatures disclosed in this specification (including any accompanyingclaims, abstract and drawings), or to any novel one, or any novelcombination, of the steps of any method or process so disclosed.

What is claimed is:
 1. A condensate pump comprising: a housing; a pumpmotor; a condensate reservoir; and a liquid level sensor mounted withinthe housing such that the liquid level sensor is located within thecondensate reservoir, wherein the liquid level sensor is configured tocontrol the pump motor, and the liquid level sensor includes a sensormodule having a first sensing element configured to generate a lowliquid level detection signal in response to a liquid reaching the firstsensing element, a second sensing element positioned above the firstsensing element and configured to generate a top liquid level detectionsignal in response to a liquid reaching the second sensing element, anda level sensing element positioned between the first and second sensingelements and configured to generate a variable liquid level signal inresponse to the liquid level rising across the level sensing element,wherein the first sensing element, the second sensing element and thelevel sensing element are operably connected to a microprocessor that isconfigured to: receive the low liquid level detection signal, the topliquid level detection signal and the variable liquid level signal;store the received variable liquid level signal in a non-volatile memoryas a low liquid level reference value upon receipt of the low liquidlevel detection signal; calculate an error value based on the variableliquid level signal and the low liquid level reference value; determinethe operating speed of a condensate pump speed based the calculatederror value; and generate a control signal to operate the condensatepump at the determined speed.
 2. The condensate pump as claimed in claim1, further comprising a third sensing element positioned above thesecond sensing element and configured to generate a high liquid leveldetection signal in response to a liquid reaching the third sensingelement, the third sensing element being operably connected to themicroprocessor, wherein the microprocessor is further configured toreceive the high liquid level detection signal.
 3. The condensate pumpas claimed in claim 2, wherein any one of the first and second sensingelements is operably connected to the third sensing element.
 4. Thecondensate pump as claimed in claim 2, wherein the high liquid leveldetection signal is a digital output signal.
 5. The condensate pump asclaimed in claim 1, wherein any one of the low or top liquid leveldetection signals is a digital output signal.
 6. The condensate pump asclaimed in claim 2, wherein the third sensing element includes a sensingarea composed of a conductive material.
 7. The condensate pump asclaimed in claim 1, wherein any one of the first, second, and levelsensing elements includes a sensing area composed of a conductivematerial.
 8. The condensate pump as claimed in claim 2, wherein thethird sensing element is a capacitance-based sensor.
 9. The condensatepump as claimed in claim 1, wherein any one of the first, second, andlevel sensing elements is a capacitance-based sensor.
 10. The condensatepump as claimed in claim 9, wherein the capacitance-based sensor is anon-contact sensor.
 11. The condensate pump as claimed in claim 1,wherein the sensor module includes a longitudinal axis, and wherein andany one of the first, second, and level sensing elements is aligned withthe longitudinal axis.
 12. The condensate pump as claimed in claim 2,wherein the third sensing element is aligned with the longitudinal axis.13. The condensate pump as claimed in claim 1, wherein the first sensingelement is operably connected to the second sensing element.
 14. Thecondensate pump as claimed in claim 1, wherein any one of the second andlevel sensing elements has a profile formed of at least two widths. 15.The condensate pump as claimed in claim 1, wherein a profile of thelevel sensing element vertically overlaps with any one of the first andsecond sensing elements.
 16. A method of controlling a condensate pumpusing a liquid level sensor, the method comprising: providing a sensormodule having a first sensing element configured to generate a lowliquid level detection signal, a second sensing element positioned abovethe first sensing element and configured to generate a top liquid leveldetection signal, and a level sensing element positioned between thefirst and second sensing elements and configured to generate a variableliquid level signal, providing a microprocessor operably connected toeach of the first sensing element, the second sensing element and thelevel sensing element, wherein the microprocessor is configured toreceive the low liquid level detection signal, the top liquid leveldetection signal, and the variable liquid level signal, and wherein themicroprocessor is further configured to control a condensate pump inresponse to the received variable liquid level signal, storing thevariable liquid level signal as a low liquid level reference value in anon-volatile memory upon receipt of the low liquid level detectionsignal, calculating an error value from the variable liquid level signaland the low liquid level reference value stored within the non-volatilememory, wherein the error value is calculated as the difference betweenthe variable liquid level signal and the low liquid level referencevalue, determining the operating speed of the condensate pump speedbased the calculated error value, and generating a control signal tooperate the condensate pump at the determined speed.
 17. The method ofcontrolling a condensate pump as claimed in claim 16, further comprisinggenerating a control signal to operate the condensate pump at a maximumspeed in response to receiving a top liquid level detection signal. 18.The method of controlling a condensate pump as claimed in claim 16,further comprising generating a control signal to shut down theconnected air-conditioning unit in response to receiving a high liquidlevel detection signal.
 19. The method of controlling a condensate pumpas claimed in claim 17, further comprising storing the value of theliquid level signal as a top liquid level reference value in thenon-volatile memory upon receipt of the top liquid level detectionsignal.
 20. The method of controlling a condensate pump as claimed inclaim 17, further comprising storing the value of the liquid levelsignal as a high liquid level reference value in the non-volatile memoryin response to receipt of the high liquid level detection signal.